Manufacture method of article similar to unglazed ceramic plate

Abstract

The invention intends to provide an interior or exterior finishing material, which is made of a clayey material as a main ingredient and is superior in water resistance and refractoriness, without consuming a large amount of energy as required in the sintering method. In a manufacture method of an article similar to an unglazed ceramic plate according to the invention, a mixture of a clayey main ingredient, a resin liquid as an agent for developing strength earlier, and a disperse solution of aluminum silicate as a weight reducing agent are used as molding materials, and the mixture is molded, dried and then heated for hardening, thereby producing a light-weight molded article that is superior in water resistance and refractoriness and is free from a whitening phenomenon. The mixture may contain a pentaerythritol aqueous solution as an agent for improving fluidity in a mixing step. Specifically, the mixture is prepared by adding 40-60 weight parts of the clayey main ingredient to a liquid having a composition of 14-17 weight parts of a solution prepared by dispersing 4-9% of aluminum silicate in a 4% polyethylene glycol aqueous solution, 5-6 weight parts of a 2% pentaerythritol aqueous solution, and 11-29 weight parts of a resin disperse liquid. The hardening under heating may be performed in the range of 110° C. to 150° C.

What is claimed is:  
     
       1. A manufacture method of an article having an appearance of an unglazed ceramic plate, said method comprising: 
       providing a mixture comprising:  
       clay,  
       a resin liquid, and a disperse solution of aluminum silicate;  
       molding said mixture;  
       drying said molded mixture;  
       heating said molded mixture for cross-linking hardening.  
     
     
       2. The manufacture method according to claim  1 , wherein said mixture contains a pentaerythritol aqueous solution. 
     
     
       3. The manufacture method according to claim  1 , wherein said mixture is prepared by adding 40-60 weight parts of said clay to a liquid having a composition of 14-17 weight parts of a solution prepared by dispersing 4-9% of aluminum silicate in a 4% polyethylene glycol aqueous solution, 5-6 weight parts of a 2% pentaerythritol aqueous solution, and 11-29 weight parts of a resin disperse liquid. 
     
     
       4. The manufacture method according to claim  1 , wherein the hardening under heating is performed in the range of 110° C. to 150° C.